Canon PIXMA MP640 User manual

MP640 / MP648
Service Manual
Revision 0
QY8-13CN-000
COPYRIGHTc2009 CANON INC. CANON MP640 082009 XX 0.00-0
Scope
This manual has been issued by Canon Inc., to provide the service technicians of this product with the information
necessary for qualified persons to learn technical theory, installation, maintenance, and repair of products. The manual
covers information applicable in all regions where the product is sold. For this reason, it may contain information that is
not applicable to your region.
This manual does not provide sufficient information for disassembly and reassembly procedures.
Refer to the graphics in the separate Parts Catalog.
Revision
This manual could include technical inaccuracies or typographical errors due to improvements or changes made to the
product. When changes are made to the contents of the manual, Canon will release technical information when necessary.
When substantial changes are made to the contents of the manual, Canon will issue a revised edition.
The following do not apply if they do not conform to the laws and regulations of the region where the manual or product is
used:
Trademarks
Product and brand names appearing in this manual are registered trademarks or trademarks of the respective holders.
Copyright
All rights reserved. No parts of this manual may be reproduced in any form or by any means or translated into another
language without the written permission of Canon Inc., except in the case of internal business use.
Copyright © 2009 by Canon Inc.
CANON INC.
Inkjet Device Market Support Management Div.
451, Tsukagoshi 3-chome, Saiwai-ku, Kawasaki-shi, Kanagawa 212-8530, Japan

TABLE OF CONTENTS
1. MAINTENANCE
1-1. Adjustment, Periodic Maintenance, Periodic Replacement Parts, and Replacement Consumables by Service
Engineer
1-2. Customer Maintenance
1-3. Special Tools
1-4. Sensors
1-5. Serial Number Location
2. LIST OF ERROR DISPLAY / TROUBLESHOOTING
2-1. Operator Call Errors
2-2. Service Call Errors
2-3. Troubleshooting by Symptom
3. REPAIR
3-1. Major Replacement Parts
3-2. Part Replacement Procedures
(1) External housing, scanner unit, and document cover removal
(2) Operation panel removal
(3) Cable wiring and connection
(4) Emblem removal
(5) Carriage unlocking
(6) ASF unit removal
(7) Carriage unit removal
(8) Spur unit and platen unit removal
(9) Purge drive system unit (right plate) and switch system unit (left plate) removal
(10) Engine unit reassembly
(11) Ink absorber replacement
4. ADJUSTMENT / SETTINGS
4-1. User Mode
4-2. Service Mode
(1) Service mode operation procedures
(2) Service Tool functions
(3) LF / Eject correction
(4) Button and LCD test
(5) Ink absorber counter setting
(6) DVD / CD print position correction
4-3. Grease Application
MP640 / MP648

4-4. Special Notes on Servicing
(1) For smeared printing, uneven printing, or non-ejection of ink
(2) Paper feed motor adjustment
(3) Carriage unit replacement
(4) Document pressure sheet (sponge sheet) replacement
(5) Ink absorber counter setting
4-5. Verification After Repair
(1) Standard inspection flow
(2) Service test print
(3) Ink absorber counter value print
5. MACHINE TRANSPORTATION
<TABLE OF CONTENTS>

1. MAINTENANCE
1-1. Adjustment, Periodic Maintenance, Periodic Replacement Parts, and Replacement Consumables
by Service Engineer
(1) Adjustment
MP640 / MP648 TABLE OF CONTENTS
Adjustment Timing Purpose Tool Approx.
time
EEPROM
initialization - At logic board replacement To initialize settings Service Tool*2
Perform in the service
mode.
1 min.
Destination
settings
(EEPROM
settings)
- At logic board replacement To set destination. Service Tool*2
Perform in the service
mode.
1 min.
Ink absorber
counter resetting
(EEPROM
settings)
- At logic board replacement
- At ink absorber replacement To reset the ink absorber counter. Service Tool*2
Perform in the service
mode.
1 min.
Ink absorber
counter value
setting
(EEPROM
settings)
- At logic board replacement To set the ink amount data in
the ink absorber to the ink
absorber counter.
Service Tool*2
Perform in the service
mode.
1 min.
Ink absorber
replacement - When the ink absorber becomes full To replace the ink absorber with a new one. Screwdriver, a pair of tweezers, etc. 15 min.
Paper feed motor
position
adjustment
- At paper feed motor
replacement To adjust the belt tension. (Position the paper feed motor
so that the belt is stretched
tight.)
None. 5 min.
CD / DVD
detection sensor
light volume
correction*1
- At carriage unit replacement
- At logic board replacement To correct the light volume for the CD / DVD detection
sensor.
Service Tool*2
Perform in the service
mode.
5 min.
Automatic print
head alignment - At print head replacement - At logic board replacement
- When print quality is not
satisfying
To secure the dot placement
accuracy. None. Perform in the user
mode.
5 min.
Manual print head
alignment 10 min.
Grease application - At carriage unit replacement
- At Easy-Scroll Wheel
replacement
To maintain sliding properties
of the carriage rail. FLOIL KG-107A 1 min.
Ink system
function check - At logic board replacement - At spur unit replacement
- At carriage unit replacement
To maintain detection
functionality for presence of
the ink tanks and each ink tank
position.
Service Tool*2
Perform in the service
mode.
1 min.
LCD language
settings - At logic board replacement To set the language to be displayed on the LCD. None. Perform in the user
mode.
1 min.
Platen glass
protection sheet
(document
pressure sheet)
- At protection sheet
replacement
- At document bottom cover
replacement
To maintain scanning
accuracy, hold the sheet with
the long side down, then fit its
upper left corner to the platen
None. 1 min.
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N: New adjustment item
*1: Only for CD / DVD printing supported regions.
*2: Install the Service Tool to a pre-registered computer.
(2) Periodic maintenance
No periodic maintenance is necessary.
(3) Periodic replacement parts
There are no parts in this machine that require periodic replacement by a service engineer.
(4) Replacement consumables
There are no consumables that require replacement by a service engineer.
position
adjustment - At scanner unit replacement glass reference mark (back left).
LF / Eject
correction - At logic board replacement - At paper feed roller
replacement
To correct line feeding (LF
roller diameter). Service Tool*2
Perform in the service
mode.
5 min.
(LF
correction
and Eject
correction
is
performed
at the
same
time.)
- At logic board replacement
- At platen unit replacement To correct line feeding (eject roller diameter). Service Tool*2
Perform in the service
mode.
Carriage rail
position
adjustment
- At carriage unit replacement
- At carriage unit removal To set the carriage rail to the original position prior to
removal or replacement of the
carriage unit, put a mark on the
main chassis before removal of
the carriage unit.
None. 1 min.
N CD / DVD print
position
adjustment
- At logic board replacement
- When printing shifts from
the correct position
To set the center of CD / DVD
printing. Service Tool*2
Perform in the service
mode.
Varies
depending
on the
degree of
print shift.
- The screws securing the paper feed motor may be loosened only at replacement of the paper feed motor
unit.
- For the automatic print head alignment, use Matte Photo Paper (MP-101), which is packed with the
machine before shipment. If Matte Photo Paper (MP-101) is not available, perform manual print head
alignment using plain paper.
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1-2. Customer Maintenance
Adjustment Timing Purpose Tool Approx.
time
Automatic print
head alignment - At print head replacement - When print quality is not satisfying
(uneven printing, etc.)
To ensure accurate dot
placement. - Machine buttons
- 1 sheet of Matte
Photo Paper
(MP-101)
- Computer (MP
driver)
5 min.
Manual print head
alignment - At print head replacement - When print quality is not satisfying
(uneven printing, etc.)
To ensure accurate dot
placement. - Machine buttons
- Computer (MP
driver)
10 min.
Print head
cleaning When print quality is not satisfying. To improve nozzle conditions. - Machine buttons
- Computer (MP
driver)
1 min.
Print head deep
cleaning When print quality is not satisfying, and not improved by print head cleaning. To improve nozzle conditions. - Machine buttons
- Computer (MP
driver)
2 min.
Ink tank
replacement When an ink tank becomes empty. ("No ink error" displayed on the monitor or on the
machine LCD, or short flashing of an ink
tank LED)
To replace the empty ink
tank. --- 1 min.
Paper feed roller
cleaning - When paper does not feed properly. - When the front side of the paper is
smeared.
To clean the paper feed
rollers of the selected paper
source (rear tray or
cassette).
- Machine
buttons
- Computer (MP
driver)
2 min.
Bottom plate
cleaning When the back side of the paper is smeared. To clean the platen ribs. (Feed the paper from the
rear tray.)
- Machine
buttons
- Computer (MP
driver)
1 min.
Scanning area
cleaning When the platen glass or document pressure sheet is dirty. To clean the platen glass and pressure sheet. Soft, dry, and clean lint-free
cloth.
1 min.
Exterior cleaning When necessary To clean the machine
exterior, or to wipe off
dusts.
Soft, dry, and
clean lint-free
cloth.
1 min.
3 / 54

1-3. Special Tools
1-4. Sensors
Click on the image to enlarge it.
Name Tool No. Application Remarks
FLOIL KG-107A QY9-0057-000 To the carriage rail sliding portions. In common with the MP610, etc.
No. Sensor Function Possible problems
1Scanner open sensor Detects opening and closing of the
scanning unit (cover). - The carriage does not move to the center even when the scanning unit is opened.
2FB encoder sensor Detects rotation of the scanner motor,
and controls scanning operation. - Faulty scanner - FB motor error
- Faulty scanned or copied images
3Inner cover sensor Detects opening and closing of the inner
cover. - The inner cover is open when it should be closed. - The inner cover is closed when it should be opened.
4PE sensor Detects the leading and trailing edges of
paper. - No paper - Paper jam
5ASF cam sensor Detects the position of the ASF cam (for
paper feeding from the rear tray). - ASF cam sensor error - Paper feeding problem
6APP encoder sensor Detects rotation of the APP encoder, and
controls paper feeding and purging
operation.
- APP sensor error
- APP position error
7Carriage encoder
sensor Detects the position of the carriage. - Carriage position error - Printing shifts from the correct position.
- Uneven printing
- Strange noise
8Temperature & Ink
amount sensor Detects the temperature of the inside of the machine and the remaining ink
amount.
- Internal temperature error
- Low-ink or out-of-ink warning
9Ink sensor Detects the position of an ink tank. - Wrong position of an ink tank
- Installation of multiple ink tanks of the same color
- No recognition of an ink tank
10 LF encoder sensor Detects rotation of the LF encoder, and
controls paper feeding. - LF position error - Uneven printing
11 Eject encoder sensor Detects rotation of the eject encoder, and
controls paper feeding. - LF position error - Uneven printing
12 Valve cam sensor Detects the position of the purge valve
cam, and controls purging operation. - Valve cam sensor error
13 Pump roller sensor Detects the position of the pump roller,
and controls purging operation. - Pump roller sensor error
14 Purge cam sensor Detects the position of the purge main
cam, and controls purging operation. - PG cam sensor error
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1-5. Serial Number Location
On the inner guide over the upper portion of the spur holder (visible when the scanning unit (cover) is opened)
When the machine power is OFF. When the machine power is ON.
<1. MAINTENANCE>
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